Method for the production of cleaning devices



July 28, 19 A. POLITZER ETAL 3,142,714

METHOD FOR THE PRODUCTION OF CLEANING DEVICES Filed Dec. 20. 1961 2 Sheets-Sheet 1 36 aw w I "mu L .jmfl W 32 jii'm, INVENTORS '-H]lll|i"----- ALFRED POLITZERJAMLS TENG .nnig mh .19 FRANK PEKAREK,PAO-CHI MNQ lmiiiliilmuh y ALVIN B. SHOCKLE F G 4 21/ Mi?) ATTORNEY July 28, 1964 A. POLITZER ETAL METHOD FOR THE PRODUCTION OF CLEANING DEVICES Filed Dec. 20, 1961 F|G.7 v

2 Sheets-Sheet 2 INVENTORS ALFRED POLlTZERgJAMES TENG, FRANK PEKAREK, PAD-CHI wwc BY ALVIN B. SHOC Y ATTORNEY United States Patent ""ce 3,142,714 METHOD FUR TIE PRODUCTION OF CLEANING DEVICES Aifred Poiitzer, tlleveland, James Tang, Parma, Frank Pekarek, (Ileveland, Aivin B. Ehcckley, Berea, and Pao-Chi Wang, fileveland, Ohio, assignors to Nylonge Corporation, Cleveland, Ghio, a corporation of Ohio Filed Dec. 20, 1961, Ser. No. 160,748 5 Claims. (Cl. 264-47) The present invention relates generally to an improved method for the production of cleaning and scouring devices and it relates more particularly to an improved method for the production of laminated cleaning and scouring devices formed of a layer of artificial sponge and a layer of a non-woven fibrous mat.

The conventional cleaning and securing devices range in character from the relatively soft highly water absorbent natural or synthetic sponge to the highly abrasive steel wool pads. These devices are particularly suited for certain limited uses but when employed for other purposes they possess numerous drawbacks and disadvantages and at best represent an unsatisfactory compromise. The sponge type device is characterized by being capable of retaining and dispensing large quantities of water and detergent solution but has a low abrasive quality. As a consequence, it is frequently necessary to employ a powdered abrasive or grit with the sponge, thus necessitating the subsequent rinsing of the secured surface and cleaning of the sponge to remove the powdered abrasive from the surface and sponge.

It has been proposed to incorporate a powdered abrasive in a synthetic sponge, but this is of little value since any abrasive that is available at the sponge surface is very shortly dissipated or masked. The common steel wool pad, on the other hand, while possessing suitable abrasive qualities, is of low water retention and rapidly deteriorates by reason of its rusting and physical disintegration. By substituting a rustproof material, such as bronze or stainless steel for the steel wool, the rusting is eliminated but the other disadvantages remain while the cost is greatly increased. Soap impregnated steel pads are likewise short-lived and the soap rapidly dissipated. All have the drawbacks of being rough on hands, and metal fiber pads frequently prick the skin and cause festering sores. Sponges formed of foamed synthetic organic thermoplastic materials have also been provided with abrasive carrying layers, but these too leave much to be desired.

It has been found that the drawbacks of the conventional cleaning and scouring devices are overcome and a highly improved product achieved by employing a regenerated cellulose sponge base upon a face of which is superimposed and secured a preferably abrasive carrying non-woven thermoplastic fiber pad or mat. There must be complete freedom of flow between the fibrous pad and the sponge member whereby the sponge member serves as a reservoir for a soap or detergent solution and the fibrous pad serves as a suds reservoir and scouring surface, the sponge feeding the pad additional detergent solution only as needed. Many difiiculties are encountered in fabricating a product of the above nature and characteristics. Where an adhesive is employed to effect the 3,142,714 Patented July 28, 1964 joining of the sponge member and the fibrous mat there results an undesirable impediment to the flow of liquid from the sponge to the fiber mat, and undesirable stiffening of the product occurs and the connection is often insecure. On the other hand, the securement of the fiber mat to the sponge member by embedding the sponge mat fibers in the sponge, per se, has been satisfactorily achieved by a procedure possessing important drawbacks. The insufiicient embedment of the fibers has resulted in the easy separation of the fiber mat from the sponge. On the other hand, it has been found that where the mat fibers are too deeply embedded in the sponge the resulting device is too stiff. In the copending patent application Serial No. 87,398, filed February 6, 1961, now Patent No. 3,109,703, in the name of Alfred Politzer et al., there are disclosed a cleaning and scouring device of the subject type and a method and apparatus for producing the same. While the method and apparatus described in the above identified patent operate satisfactorily they possess certain drawbacks and disadvantages. The end product is occasionally non-uniform and sometimes not of the best quality and close attendance and control is often required.

It is therefore a principal object of the present invention to provide an improved method for the production of cleaning and scouring devices.

Another object of the present invention is to provide an improved method for the production of cleaning and scouring devices formed at least in part of regenerated cellulose sponge.

Still another object of the present invention is to provide an improved method for securely laminating regenerated cellulose sponge and a non-woven fibrous web without impeding the flow of liquid between the sponge and fibrous web.

A further object of the present invention is to provide an improved method for the coagulation and regeneration of viscose masses.

Still a further object of the present invention is to provide an improved method of the above nature characterized by their simplicity, low cost, versatility and flexibility.

The above and other objects of the present invention will become apparent from a reading of the following description taken in conjunction with the accompanying drawing, wherein:

FIGURE 1 is a top plan view of an apparatus embodying the present invention with which the subject improved process may be practiced;

FIGURE 2 is a Vertical longitudinal elevational view thereof;

FIGURE 3 is an enlarged sectional view taken along line 33 in FIGURE 2;

FIGURE 4 is an enlarged sectional view taken along line 44 in FIGURE 1;

FIGURE 5 is a view similar to FIGURE 4 of another embodiment of the present invention;

FIGURE 6 is a view similar to FIGURE 4 of still another embodiment of the present invention;

FIGURE 7 is a view similar to FIGURE 4 of a further embodiment of the present invention; and

FIGURE 8 is a view similar to FIGURE 4 of still a further embodiment of the present invention.

In a sense, the present invention contemplates the provision of a method of producing an artificial sponge having a non-woven fibrous web adherent to a face thereof comprising the steps of transporting said web with only one face thereof exposed to a fluid sponge forming mass subjected to a pressure to effect the penetration of said sponge forming mass only partially into said web whereby the fibers of said web at the interface of said web and said sponge forming mass are embedded in said sponge forming mass, transporting said layer of said sponge forming mass carrying said web uppermost, and coagulating said layer of sponge forming mass while so transported. The process is advantageously practiced by applying the sponge forming mass, preferably having a viscose base, from a hopper or other reservoir to one face of the fibrous web while the other face is masked or protected from the sponge forming mass by suitable guide means. The web with an underlying layer of the sponge forming mass is then deposited on an endless belt conveyor with the web uppermost and transported into engagement with a longitudinally extending pair of electrodes between which a voltage is applied to effect the coagulation of the sponge forming mass.

The novel apparatus with which the present method may be advantageously practiced comprises an endless conveyor including an upper run, a reservoir for holding a viscose sponge forming mass disposed above said conveyor upper run, means guiding said fibrous web along a path exposing only one face thereof to said sponge forming mass in said reservoir and depositing a layer of said sponge forming mass upon said conveyor upper run with said fibrous web overlying said layer. In the preferred form of apparatus the reservoir is defined by a hopper having a forwardly directed discharge opening formed in its font wall directly above the upper run of the endless belt conveyor and the guide means including a roller or belt registering with the hopper discharge opening and having a bottom edge disposed above the conveyor upper run. The conveyor upper run travels along the base of a longitudinally extending trough provided with electrodes along its sides which engage the sides of the sponge forming mass layer to pass current therethrough and effect the coagulation thereof.

Referring now to the drawings and more particularly to FIGURES 1 to 4 thereof which illustrate a preferred embodiment of the present invention, the reference numeral generally designates the laminating section of the apparatus and the reference numeral 11 the sponge coagulating section. The apparatus comprises a main support frame including a pair of transversely spaced longitudinally extending channel members 12 connected by cross pieces or web 13 and supported by a plurality of suitable legs 14. Mounted on the web 13 is a trough 16 formed of wood or other suitable material and including a pair of longitudinally extending transversely spaced vertical side walls 17 located adjacent the channel mem bers 12 and a longitudinally extending base 18 supported by and between the sidewalls 17 and between the upper and lower edges thereof. The major part of the base 18 is horizontal and parallel to the Web 13 and includes a trailing section 19 which is inclined upwardly toward the trailing end of the trough 16 and a leading 20 which is inclined upwardly toward the leading end of the trough 18. It should be noted that the channel members 12 project beyond opposite ends of the trough 16.

The inner faces of the base 18 and the side walls 17 which delineate the channel 20a of the trough 16 and the top faces of the side walls 17 are lined with a suitable electrically insulating chemical resistant sheet or coating 21 such as of natural or synthetic rubber, a halogenated polyolefin or the like. Communicating with the trough channel 20a are one or more depending fluid overflow pipes 22 whose upper inlets are adjustable in height to permit the corresponding adjustment of the liquid level in the trough 16.

Suitably journalled to and between the frame channel members 12 adjacent their trailing ends and spaced a distance from the trough 16 is a first shaft 23 to which is affixed a first drum 24. Also journalled between the channel members 12 adjacent to their leading ends is a second shaft 26 on which is mounted a second or idler drum 27. A drive shaft 28 connected to a suitable drive motor and mounted on the channel member 12 by means of a suitable bearing bracket and is coupled to the shaft 23 by a worm and gear drive 30 to positively drive the shaft 23 and the drum 24.

The upper edges of the drums 23 and 27 are at the level of the corresponding upper edges of the trough base trailing and leading sections 19 and 20 and a suit ably supported horizontal plate 32 extends from the upper edge of the drum 24 to the trailing edge of the trough base section 19. A flexible endless belt 39 is advanced by and supported by and between the drums 24 and 27 and includes an upper run advancing from the apparatus trailing end to the leading end thereof and a lower return run. The belt 39 upper run extends from the drum 24 along the plate 32, the base 18 of the trough 16 includlng the trailing and leading sections 19 and 20 and to the idler drum 27. The belt return run is from the idler drum 27 along a path below the web 13 and to the drum 24 and is guided by suitably supported flanged guide Wheels 35 which engage opposite edges of the belt 39.

Located in the trough channel 20a inwardly of the side faces thereof and extending for substantially the full length of the trough 16 is a pair of transversely spaced parallel vertical electrodes 33 formed of a substantially non-corrosive metal. The electrodes 33 are supported in any suitable manner and are electrically insulated from each other, their lower edges extending substantially to the top face of the belt 39 as in traverses its upper run and the upper edges thereof projecting above the top edges of the through side wall 17. A suitable source of voltage, as will be hereinafter set forth, is connected between the electrodes 33.

A reservoir or hopper 34 containing a viscose sponge forming mass is disposed above the belt 39 and plate 32 immediately trailing the trough trailing edge and extends transversely a distance slightly less than the width of the belt 39. The hopper 34 is open bottomed and includes vertical side walls 36 substantially reaching the belt 39, and inclined rear wall 37 the lower edge of which likewise substantially reaches the belt 39, and a vertical front wall 40 having a bottom edge 41 disposed a distance above the top face of the belt 39 to delineate therewith a coating or forwardly directed discharge opening 42. It should be noted that the rear face of the front wall 40 bordering the bottom edge 41 is downwardly outwardly curved to a sharp edge.

Registering with the discharge opening 42 and extending transversely for the full width thereof is a guide roller 43 which may be an idler but which is advantageously driven at the peripheral speed of the belt 39 and is journalled to and between a pair of ears 44 formed integrally with and projecting forwardly from the hopper side walls 36. The trailing edge of the guide roller 43 is substantially coplanar with the rear face of the hopper front wall 40, and the peripheral face thereof is spaced from the hopper front wall edge 42 a distance just permitting the substantially free passage of a web W which is to be laminated to a sponge and is spaced from the belt 39 a distance substantially equal the thickness of the web W and the desired thickness of the layer of extruded sponge forming mass as assembled.

A roll R of the web W is rotatably supported on a suitably mounted shaft above and forward of the hopper 34. The web W is advantageously a low density, highly porous compressible resiliently non-woven web of fibers with intercommunicated voids of between 75% and of the web volume which is preferably of the type described in US. Patent No. 2,958,593 granted November 1, 1960, to H. L. Hoover, et al., or other suitable nonwoven thermoplastic fibrous mass of such characteristics preferably carrying adherent abrasive finely divided materials.

Considering now the dimensions and operating parameters of the machine described above, the width of the trough and corresponding components may be as desired, for example about 20 to 40 inches, and the length of the trough 16 between the inner edges of the trailing and leading sections 19 and 20 may be between about 6 and 15 feet, for example 9 feet, and the base thereof inclined between 3 and 8, preferably between 3 and 6 for example 4". The longitudinal dimension of the downwardly directed bottom opening of the hopper 34 is advantageously between 2 and 8 inches and preferably between 2 and 6 inches, for example 6 inches and the height of the discharge opening 42 is advantageously be tween 3 and 5 inches, preferably between 3 /2 and 4 /2 inches, and the diameter of the roller 23 is correspondingly dimensioned as aforesaid. The head of the mass V in the hopper is advantageously between 4 and 16 inches, preferably between 8 and 16 inches, for example inches. The rate of advance of the belt 39 is advantageously between 5 and 12 inches per minute, preferably in excess of 7 inches per minute, for example 8 inches per minute. The height of the liquid L in the trough 16 which liquid is evolved from the coagulated sponge mass is such as to reach a point preferably at or slightly below the level of the interface of the web W and the sponge body M as they are transported by the belt 39 along the low point of the trough 16. The liquid level is achieved by means of the overflow pipes 22. Openings may be provided in the electrodes 33 to permit the passage of liquid and the level thereof is below the upper edge of the trough. While it is desirable to apply the commercially available 110 volt 60 cycle AC. voltage between the electrodes 22, the voltage may be varied but is advantageously between 80 and 300 volts and alternating. The current density through the viscose sponge mass is advantageously between 1 and 3 amperes per square inch, preferably less than 2 amperes, for example 1.2 amperes per square inch. It should be noted that the viscose sponge forming mass is coagulated but not regenerated before immersion in the liquid L and the cellulose is regenerated when the mass is exposed to the liquid. The viscose mass before immersion is raised by resistance heating to a temperature preferably not exceeding 60 C. and when exposed to the liquid L its temperature is raised above 80 C. preferably between 90 C. and 105 C., for example 100 C.

The distance and time the viscose mass carrying web travels in engagement with the electrodes 22 prior to immersion in the liquid L is advantageously 20 to 40 inches for 5 to minutes, preferably to 30 inches for 5 to 10 minutes for example 30 inches for 6 minutes duration. The electrode contact time while immersed is advantageously 15 to 20 minutes preferably 10 to 15 minutes for example 10 minutes and the distance traveled during immersion is advantageously 30 to 90 inches, preferably 40 to 80 inches, for example 60 inches.

In practicing the present process with the equipment described above a green viscose is produced in the conventional manner having a cellulose content between 7 and 10%, for example 8.0% an alkalinity between 5 and 7.5% for example 5.6%, a total sulfur content of between 2.5% and 4.0%, for example 3.2% and a viscosity of 200500 seconds, for example 300 seconds as measured by the fall of a inch diameter ball for 8 inches. With 100 pounds of viscose there is admixed 200 to 350 of sodium sulphate decahydrate crystals of a size between 40 mesh and /2 inch, for example 280 pounds of crystals /3 of which is inch, /3 is 4 mesh and /3 is 10 mesh, and 1 to 2.5 lbs. cut flax fibers, for example 1.6 pounds. The resulting viscose sponge form- 6 ing mass, at a temperature advantageously between 10 C. and 23 (3., preferably between 15 C. and 20 C., for example 18 C. is introduced into the hopper 34 and the apparatus 13 operated in accordance with conditions and parameters given above by way of specific example.

The web W is of the type described in the above identified Hoover et al. patent and may be any desired thickness, preferably between /s inch and /2 inch, for example inch and is guided about the periphery of the roller 43 into contact with the sponge forming mass V which penetrates the web W as aforesaid about inch. A layer of viscose sponge forming mass V is deposited on and conveyed by the travelling belt 39 and carries with it the partially embedded superimposed web W. It should be noted that the depth of penetration depends on the dimensions of the hopper opening, the pressure head on the mass M as well as the viscosity thereof and the rate of travel of the belt 39. Moreover, in order to facilitate the penetration of the web W by the mass V prior to the passage of the web W beneath the hopper 46 the upper surface thereof may be wetted with water, an aqueous solution of a surface active agent such as for example the alkyl sulfonates, the quaternary ammonium compounds, sulfoscuccinates, or with a dilute viscose or alkali solution. In addition, the surface of the belt 39 may be provided with any desired pattern, for example a waflied pattern, to correspondingly emboss the surface of the resulting sponge and also to increase the frictional drag of the belt on the mass V and the resulting sponge.

As the web carrying viscose layer is transported between the electrodes 33 and before immersion thereof, it reaches a temperature of about 30 C. within about 4 minutes at which time the viscose is substantially completely coagulated and there is no significant regeneration of the cellulose. After passage through the heated liquid L the sponge forming mass is raised above the cellulose regeneration temperature and almost complete regeneration is effected before the sponge layer M leaves the liquid L. In the above example complete coagulation and regeneration is effected in about 15 minutes in contrast to the time of 45 minutes required according to conventional procedures. Following the trough 16 the laminated web and sponge may be Washed, bleached, and plasticized or dried, or impregnated with soap or detergent and then cut and packaged.

It has been found that the coagulation and regeneration of the sponge web assembly with the web uppermost in the manner described above is simpler, more convenient and results in a superior product. A high quality product is uniformly achieved and the web W is not adversely effected by the constituents of the sponge forming mass or leached liquid L.

In FIGURE 5 of the drawings there is illustrated another form of apparatus differing from that first described only in the positioning of the guide roll. Specifically an open bottom hopper 50 for the sponge forming mass V is disposed above the belt 39 and plate 32 and includes a front Wall 51 having a bottom edge located above the belt 39. A transversely extending lip plate 52 is affixed to the front wall 51 by screws 53 and is suitably vertically adjustable thereon. The lower edge of the lip plate 52 delineates with the upper surface of the belt 39 a for wardly directed discharge opening 54 the height of which is adjustable by adjusting the lip plate 52. A transversely extending idler guide roller 56 registers with the discharge opening 54 with its lower edge above the belt 39 and its upper edge below the lip plate 52 the distances earlier set forth. The roller 56 is mounted on a shaft 57 which lies in the plane of the plate 53 so that the web W is exposed to the mass V for about about the roller 56. The shaft 57 and roller 56 are adjustable vertically and longitudinally in any suitable manner to vary the position of the guide roller in the discharge opening and hence the exposure time of the web W to the mass V and the amount of embedment therein, and the thickness E of the layer of sponge forming mass V deposited on the belt 39. The lip plate 52 permits the adjustment of the discharge opening to match the position of the roller 56.

The operation of the apparatus described above is similar to that first described.

Referring now to FIGURE 6 of the drawing which illustrates another embodiment of the present invention differing from those earlier described in the provision of a second web guide member. The hopper 66 includes the front wall 61 whose lower edge defines with the belt 39 a forwardly directed discharge opening. A guide roller 63 registers with the discharge opening and is journalled to and between the ears 64 projecting forwardly from the hopper side walls. A second transversely extending guide roller or rod 65 is supported by and between the cars 64 and is vertically and longitudinally adjustable in any suitable manner. The web W travels beneath the guide rod 65 and thence to the upper surface of the guide roller 63. The guide rod 65 permits a greater exposure time of the web to the mass in the hopper 60 by increasing the peripheral surface of the roller 63 engaged by the web W and the amount of insertion thereof into the hopper carried mass V.

In the embodiment of the invention illustrated in FIG- URE 7 of the drawing there is substituted for the guide roller of the previously described embodiment a driven endless belt. The open bottomed hopper 70 is disposed above the belt 39 and plate 52 and includes a front wall 71 having a lower edge disposed above the belt 39 to delineate therewith a forwardly directed opening 72, and side walls 73 provided with lower forwardly directed panels 74. A pair of vertically spaced parallel transversely extending upper and lower drums 76 and '77 respectively is disposed above the belt 39*. An endless feed belt 78 passes around and is supported and driven by the drums 76 and 77, and includes a rear vertical run registering with the opening 72 and located shortly forward of the front face of hopper wall 71 and extends above the lower edge thereof. At least one of the drums 77, 76 is positively driven so that the linear speeds of the belts 39 and 78 are substantially equal.

In operation, of the apparatus last described, the web W is guided into the space between the rear vertical run of the belt 78 and the confronting face of the hopper wall 71 and is advanced by the belt 78 along the opening 72 where it is exposed to the sponge forming mass V in the hopper 70. The web W and an underlying layer of mass V are carried by the belt 39 through the slot delineated by the bottom run of the belt 78 and the upper run of belt 39 and to further processing as earlier described.

Referring now to FIGURE 8 of the drawings which illustrates a further embodiment of the present invention which differs from the earlier described embodiments in the structure of the laminating section, the sponge coagulating section and the endless conveyor belt 39 remaining unchanged. The laminating section comprises a transfer and inverting mechanism 80 including a front transversely extending suitably mounted upper drum 81 and a second rear transversely extending lower idler drum 82 parallel to and of smaller diameter than the drum 81. An endless belt 85, of substantially the width of the conveyor belt 39 passes about and is supported by and between the front and rear drums 81 and 82 and has a. rearwardly downwardly inclined upper run 83 a forwardly upwardly inclined bottom run 84 and a rear end run 86 about the drum 82, the lowest point of the belt 85 being at the bottom of the end run 86 and being above the upper face of the conveyor belt 39 a distance about equal to the thickness of the assembled web W and the underlying layer of sponge forming mass V. The drum 81 is positively driven counter-clockwise as viewed in FIGURE 8 to advance the belt 85 along its upper run 83 rearwardly in a direction opposite to the advance of the conveyor belt 39 along its upper run.

Located directly above the upper run 83 of the transfer belt is a hopper 87 containing a fluid sponge forming mass V and having a front wall 88 provided with a horizontal transverse bottom edge located above the belt upper run 83 a distance slightly greater than the thickness of the web W and a rear wall 89 provided with a horizontal transverse bottom edge located above the belt upper run a distance substantially equal to the thickness of the assembled web W and the underlying extruded layer of sponge forming mass V. A transversely extending guide rod 90 is disposed rearwardly and shortly above the bottom edge of the hopper front wall 88.

In operation, the web W is guided from a roll thereof under the rod 90 and is carried by the belt 85 along its upper run 83 under the bottom edges of the hopper walls 88 and 89 in registry with the hopper bottom opening where it is exposed to the sponge forming mass V whose head is as earlier set forth, penetrates the web W a predetermined depth so that the fibers along the web sponge mass interface are embedded into the sponge mass. As the web W emerges from the hopper it carries with it a superimposed layer of the sponge forming mass V, the thickness of which is determined by the height of the bottom edge of the rear hopper wall 39. The belt 85 transports the sponge mass layer carrying web W around the end run 86 to invert the sponge mass layer and web assembly and deposit it upon the advancing belt 39 with the layer of sponge forming mass resting directly on the belt 39 and the web W being uppermost and superimposed on the sponge forming layer. The assembly is transported by the belt 39 and treated in the manner earlier described.

While there have been described and illustrated preferred embodiments of the present invention, it is apparent that numerous alterations, omissions and additions may be made without departing from the spirit thereof.

What is claimed is:

1. The method of producing a regenerated cellulose sponge having a non-woven fibrous web adherent to a face thereof comprising the steps of transporting said web with only one face thereof exposed to a viscose sponge forming mass subjected to a uniform predetermined pressure corresponding to a head of at least 4 inches of said viscose sponge forming mass to effect the penetration of said viscose sponge forming mass only partially into said web whereby the fibers of said web at the interface of said web and said sponge forming mass are individually embedded in said viscose sponge forming mass, depositing a layer of said viscose sponge forming mass with said partially embedded web superimposed thereon upon an advancing endless belt, and coagulating said viscose sponge forming mass while transported by said belt.

2. The method according to claim 1, wherein said viscose sponge forming mass is coagulated by passing an electric current therethrough in a direction substantially perpendicular to the direction of travel thereof.

3. The method according to claim 1, wherein said sponge forming mass adheres to said belt during the coagulation thereof.

4. The method according to claim 1, wherein the pressure in said viscose sponge forming mass is sufficient to imbed said web face therein between and inch.

5. The method of producing a regenerated cellulose sponge having a non-woven fibrous web adherent to a face thereof comprising transporting said web along a path in registry with a discharge opening in a reservoir of a viscose sponge forming mass under a predetermined head in excess of 4 inches of said viscose sponge forming mass whereby said viscose sponge forming mass only partially penetrates said web along one face thereof, and depositing a layer of said sponge forming mass with said fibrous web superimposed uppermost thereon upon an endless conveyor underlying said reservoir.

(References on following page) References Cited in the file of this patent UNITED STATES PATENTS Bendall Feb. 1, 1881 De Nooij et a1 May 18, 1943 Pearson June 8, 1948 Berger June 19, 1951 Alderfer Aug. 18, 1953 Land Dec. 1, 1953 Alderfer June 26, 1956 Cubberly Oct. 23, 1956 Von Kohorn Mar. 25, 1958 

1. THE METHOD OF PRODUCING A REGENERATED CELLULOSE SPONGE HAVING A NON-WOVEN FIBROUS WEB ADHERENT TO A FACE THEREOF COMPRISING THE STEPS OF TRANSPORTING SAID WEB WITH ONLY ONE FACE THEREOF EXPOSED TO A VISCOSE SPONGE FORMING MASS SUBJECTED TO A UNIFORM PREDETERMINED PRESSURE CORRESPONDING TO A HEAD OF AT LEAST 4 INCHES OF SAID VISCOSE SPONGE FORMING MASS TO EFFECT THE PENETRATION OF SAID VISCOSE SPONGE FORMING MASS ONLY PARTIALLY INTO SAID WEB WHEREBY BY FIBERS OF SAID WEB AT THE INTERFACE OF SAID WEB AND SAID SPONGE FORMING MASS ARE INDIVIDUALLY EMBEDDED IN SAID VISCOSE SPONGE FORMING MASS, DEPOSITING 